Methods of treatment of laminated timber

ABSTRACT

The invention relates to methods to thermally treat wood (e.g., flat-grain timber) to produce wood with enhanced color and/or weathering properties.

The present application claims priority to priority applicationNZ707743, filed May 7, 2015, which is herein incorporated by referencein its entirety.

TECHNICAL FIELD

The invention relates to methods to thermally treat wood (e.g.,flat-grain timber) to produce wood with enhanced color and/or weatheringproperties.

BACKGROUND ART

Softwood species including radiata pine (“radiata”), southern yellowpine, scots pine, ash, maple, beech, birch, aspen and rubber wood areused in a number of exterior construction applications such asstructural members (for example, weight bearers and joists), decking andcladding. Many softwood species, and especially radiata, havedisadvantages including lack of dimensional stability in service“stability”, surface checking and poor colour/aesthetics followingexposure. These have resulted in softwood timbers being unable tocompete in some market applications with more durable and aestheticallypleasing timbers such as Western Red Cedar for cladding and hardwoodssuch as Kwila (also known as Merbau), for decking. Consequently, somesoftwood species and radiata pine in particular are viewed as a low-costcommodity material for decking and cladding applications.

When used for decking applications, low cost species such as radiata areoften supplied in a form known as “wet, treated” which is very prone toshrinkage as the moisture content of the timber equilibrates to thesurrounding conditions. This shrinkage results in unsightly dimensionalchanges. Furthermore, radiata in particular is not perceived to havepleasing aesthetics in its natural state. However, painting to overcomethe lack of aesthetics is not practical for decking applications.Coatings and stains can be applied but these add cost and inconvenience.As a result of these disadvantages, radiata pine in a “wet, treated”format is not considered a premium decking material and is often seen asa cheap decking option by the market.

In cladding applications radiata is generally painted, typically withlighter colours. Painting not only results in a better surface finish,but it also ensures increased stability of the timber and enhances itsaesthetic appeal. This is because, if it is not painted, the radiataused for cladding, like the “wet, treated” timber in deckingapplications, is not always stable and has a propensity to distort (or“warp”) and surface check when exposed to varying climatic conditions.

Use of some softwood species (radiata in particular) in cladding anddecking applications does, however, have some advantages, particularlyover the hardwoods. These advantages typically relate to cost and toenvironmental concerns. For example, harder, more durable species (oftenhardwoods) are often slow growing and exist within naturally-occurringtropical forests resulting in environmental concerns amongst the generalpublic. By comparison, softwood species such as radiata can be grown asplantation species which are quick growing, continually re-forested and,as such, sustainably grown. Radiata or other plantation species are alsoreadily available in most countries. The rapid growth rate of suchplantation species compared to non-plantation species such as hardwoodsmeans the trees can be harvested earlier and this, along with readyavailability, leads to cost benefits. In addition, prices of manyhardwood species are increasing around the world due to their decliningavailability.

The use of preservatives and timber modification techniques are known toprovide means for increasing the durability of soft woods such asradiata. These techniques are well known and provide optionsindividually or together in combination to increase the durability ofsoftwoods such as radiata.

To improve the stability of timber, it is known to laminate individualboards together. It is known in the art that boards with a verticalgrain orientation are more resistant to warping, splitting and surfacechecking and are thus more stable when used. Laminated wooden boards aretypically produced by gluing together individual boards in a flat grainorientation edge to edge or face to face to give individual finishedboards with a flat or mixed grain orientation. However, lamination inthis way typically results in finished boards of flat or mixed grainorientation that are more prone to surface checking and movement. Italso results in unsightly glue lines in the finished product. An exampleof such lamination techniques is shown in NZ 562263 to LockwoodBuildings Limited.

It is an object of the present invention to provide a method of usingtimber boards with a substantially flat grain to produce a thermallymodified timber product with enhanced dimensional stability andaesthetic characteristics, or at least to provide the public with auseful choice.

SUMMARY OF THE INVENTION

In some embodiments, provided herein are methods of treating woodcomprising: a) thermally treating moisture reduced wood at temperatureof about 205-245 C for about 1.5 to 6.0 hours to generate thermallytreated wood, wherein the moisture reduced wood has a moisture contentof less than about 1%; and b) cooling and hydrating the thermallytreated wood such that modified wood is generated, wherein the modifiedwood has a moisture content of about 4-10 percent.

In certain embodiments, the methods further comprise a step before stepa) of heating original wood (e.g., sawn timber) to a temperature ofabout 115 to 145 C to reduce the moisture content of the wood togenerate the moisture reduced wood.

In further embodiments, the thermally treating the moisture reduced woodis at a temperature of about 215-225 C.

In other embodiments, the thermally treating the moisture reduced woodis for a time of about 2.5 to about 3.5 hours.

In some embodiments, the moisture reduced wood has a moisture content ofabout 0%.

In other embodiments, the thermally treating moisture reduced wood isperformed in a Kiln or other heating device.

In particular embodiments, the cooling (e.g., to room temperature) andhydrating is performed in the kiln. In certain embodiments, theconditions (e.g., moisture and temperature) inside the kiln are computercontrolled to ensure the proper moisture content of the finished wood.

In some embodiments, the cooling and hydrating comprising providingsteam to the wood.

In further embodiments, the modified wood has a moisture content ofabout 6.5 to 7.5%.

In additional embodiments, the moisture reduced wood is a soft wood.

In additional embodiments, the modified wood is laminated to other woodsimilarly treated to create a laminated board comprising a glue line.

In particular embodiments, the laminated board is sawn perpendicular tothe glue line.

In other embodiments, the moisture reduced wood is a species selectedfrom the group consisting of: radiata pine, southern yellow pine, scotspine, ash, maple, beech, birch, aspen or rubber wood.

In certain embodiments, the methods further comprise treating thelaminated board to add one or more striations.

In other embodiments, the modified wood has a lightness L-value of lessthan 62 as measured by the CIELAB Color Space.

In certain embodiments, the contrast in lightness between layers in thelaminated board is less than L=10 when assessed using the CIELAB colourspace.

In some embodiments, the laminated board is coloured to mimic the colourof a different wood.

In additional embodiments, the different wood is Western Red cedar,Kwila, Teak, Vitex, Ipe, Balau or Bankirai.

In some embodiments, provided herein are articles of manufacturecomprising the modified wood generated by the methods described herein.

In one aspect the invention provides a method of using timber boardswith a substantially flat grain to produce a laminated board withenhanced dimensional stability and aesthetic characteristics, the methodcomprising:

-   -   a. taking at least two timber boards originally cut from a tree        in a substantially flat grain orientation;    -   b. laminating a flat grain face of each board together by gluing        to produce a laminated block;    -   c. cutting the laminated block substantially perpendicular to        the grain to produce laminated boards comprising a front and        back face having the appearance of a substantially vertical        grain and showing at least one glue line    -   wherein the method comprises treatment and colouring of the        timber boards, laminated block or laminated boards by thermal        modification.

In a particular embodiment, the method further comprises surfacefinishing comprising the addition of one or more striations to the frontor back face of the laminated boards.

In a particular embodiment, the addition of one or more striationsreduces visibility of at least one glue line.

In a particular embodiment, thermal modification reduces visibility ofat least one lamination glue line.

In a particular embodiment, thermal modification reduces contrastbetween two or more lamination layers.

In certain embodiments of the methods and compositions therein, thecontrast in lightness between layers in the laminated board is less thanL=10 when assessed using the CIELAB colour space (e.g., 10% less . . .20% less . . . 50% less . . . or 80% less than L=10).

In a particular embodiment, thermal modification is carried out at atemperature between 180° C. and 240° C. (e.g., 180 . . . 195 . . . 220 .. . and 240° C.).

In a particular embodiment, thermal modification is carried out for aperiod between 1 and 6 hours (e.g., 1 . . . 3 . . . 5 . . . and 6hours).

In a particular embodiment, thermal modification is carried out at atemperature between 180° C. and 240° C. for a period between 1 and 6hours.

In a particular embodiment, thermal modification is carried out at atemperature between 200° C. and 240° C. for a period of between 2 and 4hours.

In a particular embodiment, thermal modification is carried out atbetween 200° C. and 240° C.

In a particular embodiment, thermal modification is for a period ofbetween 2.5 and 3.5 hours or approximately 3 hours.

In a particular embodiment, the lightness L-value of the board isreduced by thermal modification to less than 62 (e.g., 61 . . . 55 . . .40 . . . 25), as measured by the CIELAB Color Space.

In a particular embodiment, the thermal modification step providespreservative properties to the timber. In a particular embodiment, themethod of processing timber does not include the step of treating thetimber with a chemical preservative compound (e.g., the produced timeris added preservative-free).

In a particular embodiment, the timber comprises a softwood or ahardwood species. In a particular embodiment, the timber comprisesradiata pine, southern yellow pine, scots pine, ash, maple, beech,birch, aspen or rubber wood.

Colouring the timber is achieved by at least one of:

-   -   (i) thermal modification;    -   (ii) furfuryl modification;    -   (iii) resin impregnation;    -   (iv) use of a colourant;    -   (v) use of a preservative that has an inherent colour due to its        chemistry e.g. alkaline copper quaternary (ACQ).

Preferably, thermal modification is carried out prior to lamination.Preferably, thermal modification is carried out prior to applying apreservative.

Preferably the surface finishing comprises the addition of striationsselected from the group consisting of less than 2.5 mm width, less than1 mm width, approximately 2.5 mm width and approximately 1 mm width.

Preferably, the step of colouring the timber is achieved by carrying outthe step of treating the timber using thermal modification.

In a further embodiment, the timber may undergo one or more furthertreatments to increase surface hardness, dimensional stability and/ordurability. Suitable treatments include furfuryl modification and resinimpregnation.

In a particular embodiment, lamination to produce the appearance of avertical grain orientation on a surface of the timber comprises:

-   -   i. taking at least two boards originally cut from a tree in a        substantially flat grain orientation;    -   ii. laminating a flat grain face of said boards together by        gluing to produce a laminated block;    -   iii. cutting the laminated block substantially perpendicular to        the grain to produce individual boards with the appearance of a        substantially vertical grain orientation.

Preferably the colourant is a naturally occurring pigment or a dye.Preferably the colourant is not chemically synthesized.

Preferably the surface of the timber is finished using striations thatare produced by at least one of:

-   -   (i) a band-sawn effect, preferably applied during band sawing of        the laminated block into individual boards;    -   (ii) a micro-reed effect, preferably applied during profiling of        the boards in a timber planar operation;    -   (iii) a brushed effect, preferably applied using a brushing        tool. Preferably, the brushing tool is a metallic brushing tool        that is a stand-alone piece of equipment or has been adapted to        be used in a stand-alone timber planar operation.

In a further aspect, the invention provides a laminated timber productproduced by any of the above methods.

In a further aspect the invention provides a laminated timber productwith enhanced dimensional stability and aesthetic characteristicswherein:

-   -   a. the timber has undergone thermal modification.    -   b. the product is laminated and cut to produce the appearance of        a vertical grain orientation on a face of the timber; and    -   c. the timber has been coloured.

In a further aspect the invention provides a timber product wherein:

-   -   a. the timber has undergone thermal modification.    -   b. the product is produced from boards originally cut from a        tree in a substantially flat grain orientation that have been        laminated and cut perpendicular to the grain to give the        appearance of a vertical grain orientation on a face of the        timber, wherein the face of the timber shows laminated layers        divided by glue lines; and    -   c. the timber has been coloured.

In a particular embodiment, the surface of the laminated timber producthas a surface finish comprising one or more striations.

In a particular embodiment, the thermal modification process preservesthe timber.

In a particular embodiment, the timber product comprises a softwood or ahardwood timber species. In a particular embodiment, the timbercomprises radiata pine, southern yellow pine, scots pine, ash, maple,beech, birch, aspen or rubber wood.

In a further aspect, the invention provides a method of processingtimber to enhance the dimensional stability and aestheticcharacteristics of the timber, the method comprising the steps of;

-   -   a. treating the timber using thermal modification;    -   b. colouring the timber; and    -   c. lamination to produce the appearance of a vertical grain        orientation on a face of the timber.

In a further aspect, the invention provides a laminated timber productwherein

the surface of the timber has a surface finish comprising striations todisguise or reduce the visibility of one or more glue lines from thelamination process; and wherein

the timber is coloured to mimic the colour of a different wood; andwherein

the timber is thermally modified.

The invention may also be said broadly to consist in the parts, elementsand features referred to or indicated in the specification of theapplication, individually or collectively, in any or all combinations oftwo or more of said parts, elements or features.

Further aspects of the invention, which should be considered in all itsnovel aspects, will become apparent to those skilled in the art uponreading of the following description which provides at least one exampleof a practical application of the invention.

DESCRIPTION OF THE FIGURES

Embodiments of the invention will now be described, by way of exampleonly, with reference to the accompanying drawings in which:

FIGS. 1 to 4 show the appearance of laminated radiata pine boardsprepared according to the processes of the invention after brushing.

FIGS. 5 to 8 show the appearance of laminated radiata pine boardsprepared according to the processes of the invention with a band sawnfinish.

FIG. 9 shows exposure test site and test racks.

FIG. 10 shows coated thermally modified timber boards installed on testracks.

FIG. 11 shows coated ACQ boards 6 months after the start of the exposuretrial with delamination at ends evident

FIG. 12 shows coated ACQ boards 12 months after the start of theexposure trial with partial delamination evident in the middle of theboard.

FIG. 13 shows coated ACQ boards 12 months after the start of theexposure trial with partial delamination evident in the middle of theboard.

FIG. 14 shows coated ACQ boards 12 months after the start of theexposure trial with partial delamination evident.

FIGS. 15 and 16 show coated thermally modified timber boards after 24months exposure—the coating has started to fail, but the substrate isstable with no delamination evident.

FIG. 17 shows timber sawn from a tree with flat grain 1, vertical grain2, rift sawn 3 and mixed grain 4).

DETAILED DESCRIPTION Definitions

“Softwood” means wood from gymnosperm trees. Gymnosperms reproduce byforming cones which emit pollen to be spread by the wind to other trees.Pollinated trees form naked seeds which are dropped to the ground orborne on the wind so that new trees can grow elsewhere. Some examples ofsoftwood include pine, redwood, douglas-fir, cypresses and larch.

“Hardwood” means wood from angiosperm trees. Angiosperms produces seedswith some sort of covering such as a shell or a fruit. Angiospermsusually form flowers to reproduce. Birds and insects attracted to theflowers carry the pollen to other trees and when fertilized the treesform fruits or nuts and seeds. Hardwoods include eucalypts, beech andblackwood.

A “board” is defined as a piece of timber sawn from a tree with a widthgreater than a depth, and a length greater than the width. The face ofthe board is defined as a plane with edges defined by the width and thelength of the board. A cross sectional view of the board through thewidth and depth axis will typically be substantially rectangular. Boardsmay be cut from the tree in a variety of orientations as shown in FIG.17 and described in further detail below.

“Dimensional stability” or simply “stability” means the degree ofresistance to deformation, expansion or shrinkage that can result fromchanges in conditions such as temperature and humidity.

“Durability” means the degree of resistance to decay as a result offungal or microorganism growth and degradation.

“Aesthetic characteristics” means the visual appearance of the timber,taking into account the colour, texture, presence of glue lines,contrast between lamination layers and grain orientation.

Unless the context clearly requires otherwise, throughout thedescription and the claims, the words “comprise”, “comprising”, and thelike, are to be construed in an inclusive sense as opposed to anexclusive or exhaustive sense, that is to say, in the sense of“including, but not limited to”.

The present invention is directed to a method for processing flat graintimber to improve the stability and aesthetic characteristics of thetimber. Flat grain timber has a lower value than vertical grain timberand in its natural state has the tendency to lack dimensional stability.The inventors have developed an improved method of processing flat grainlaminated timber to yield a product with enhanced weatheringperformance, dimensional stability and aesthetic qualities when comparedto previous laminated timber products. One key reason for this is to beable to mimic the appearance and stability characteristics of moreexpensive hardwood timbers. The method is applicable to modify anyspecies to impart more desirable aesthetic/stability properties. Inparticular embodiments, the processed timber is a softwood species. Byway of example, the timber is selected from the group consisting ofradiata pine, southern yellow pine, scots pine, ash, maple, beech,birch, aspen or rubber wood.

Production of flat-grain laminated timber is extremely limited due tothe need to process the wood and the cost this adds to the finalproduct. For high throughput timber operations this is undesirable andadds cost to what is a commodity product. The inventors have recognisedthat there may be niche market for sustainably products produced fromflat-grain timber. From an economic point of view, the upgrading oflower value materials to higher value niche products is desirable forsmaller scale producers. A further reason for lack of use of flat grainlaminated timber is the undesirable effect of visible glue lines, andthe contrasting colour tone between the layers in the laminated boards.The inventors have carried out testing of different methods to mitigatethese drawbacks and found that they can be effectively addressed bythermal modification of the wood and optionally the addition ofstriations and/or coloured glue to reduce the visibility of the gluelines.

The inventors have also surprisingly found that thermal modification offlat grain laminated timber provides a product with increased stabilityand a lower propensity to delaminate during prolonged exposure. Thethermal modification step combines with the lamination step to preventdeterioration of the timber and provide stability more akin to moreexpensive hardwoods often harvested unsustainably from primary forests.The tendency for partial delamination to occur in thermally modifiedtimber is reduced when compared to preservative treated timber.

Colouring enhances the aesthetic characteristics of the wood bymimicking the appearance of more expensive timbers, and reducing thevisibility of the glue lines produced by the lamination process. Theinventors have therefore provided a complete solution to the problem ofusing flat grain timber from cheaper, sustainably grown, mainly softwoodspecies (e.g. radiata) in place of more desirable vertical grain timberor timber from (often more expensive) predominantly hardwood species.

The invention provides a method of processing timber comprising thermalmodification, colouration and lamination. In some embodiments, surfacetreatment capable of resulting in striations acts to further camouflagethe lamination glue lines. One overall effect of the method is to mimicWestern Red Cedar, Kwila, Teak, Vitex, Ipe, Balau, Bankirai or othercommonly used hardwood timbers. The processed timber can therefore besafely used in outdoor applications, such as decking or cladding, inplace of these species of timber. Since most chemical preservatives aretoxic, the timber of the present invention (when not treated with achemical preservative compound) is acceptable for uses that have strictsafety standards such as children's play equipment, cladding anddecking, and in sustainable building design. Further, the use ofcheaper, lower grade timber is made possible by the lamination processwhich makes use of the less desirable cuts of wood from a tree. Coupledwith the ease of disposal of the non-preservative treated timber, theinvention provides an important advance in the timber industry and animportant resource for sustainable and safe structures.

Accordingly, in a first aspect, the invention provides a method of usingtimber boards with a substantially flat grain to produce a laminatedboard with enhanced dimensional stability and aesthetic characteristics,the method comprising:

-   -   a. taking at least two timber boards originally cut from a tree        in a substantially flat grain orientation;    -   b. laminating a flat grain face of each board together by gluing        to produce a laminated block wherein each board comprises a        laminated layer;    -   c. cutting the laminated block substantially perpendicular to        the grain to produce laminated boards comprising a front and        back face having the appearance of a substantially vertical        grain and showing at least one glue line    -   wherein the method comprises treatment and colouring of the        timber boards, laminated block or laminated boards by thermal        modification.

One important aspect of the invention is the ability to use flat grainboards to achieve the appearance of a vertical grain on the face of theboard. Flat grain timber is generally less valuable and less desirablethan vertical grain timber due to its increased tendency to warp, splitand surface check during use. The invention therefore provides the userwith a method of extracting more value from a finite resource andcontributing to the sustainable use of land and forests.

Lamination provides enhanced stability to the timber product (i.e. thelaminated board) which cannot be achieved by thermal modification aloneas well as a more aesthetically pleasing appearance of a vertical grainorientation when cut to achieve that effect. The invention relates totimber boards which are originally cut from a tree with a substantiallyflat grain orientation. FIG. 17 shows the timber sawn from a tree withflat grain 1, vertical grain 2, rift sawn 3 and mixed grain 4). Eachboard is cut along a plane defined by the width and depth, the length ofboard extending along the log. The width of the cuts in FIG. 17 beinggreater than the depth. The length of the board may be any length. Asubstantially flat grain orientation means any board with annual ringsfrom 0° to 35° to the edge of the board. A riftsawn board has annualrings from 35° to 65° to the edge of the board and a vertical grain (orquartersawn) board has annual rings from 65° to 90° to the edge of theboard. It will be appreciated by those of skill in the art that thelaminated boards claimed as the invention will be composed of a majorityof flat grain timber. However, in certain embodiments, there may be upto 20% of a cross section width of the final laminated boards that ismade up of rift sawn or vertical grain timber. At least two flat-grainboards are laminated together by gluing to form a laminated blockwherein each original board comprises a laminated layer. The block isthen cut substantially perpendicular to the grain to produce individuallaminated boards. Each laminated board comprises a front and a back faceshowing at least one glue line between the laminated layers and saidfaces have the appearance of a substantially vertical grain orientation.This technique produces boards with glue lines at the join of eachoriginal board which extend along the length of the laminated board.Timber processed in this way is more resistant to warping, splitting andsurface checking and therefore more stable when used. The methods of theinvention may comprise lamination with a coloured, colourless or tintedglue to produce the appearance of a vertical grain orientation on theface of the board.

In general, it is important that the boards being laminated areappropriately selected and aligned or arranged so that the surface ofthe final cut board has a vertical grain appearance. However, thelamination process typically results in the appearance of unsightly gluelines in the final cut timber product. Thermal modification andstriations as described below help to mitigate this problem and thusfurther increase the value of the timber product. Other ways to mitigatethe unsightly glue lines are to use a colourless glue is employed duringthe lamination process. Alternatively, a glue tinted to substantiallymatch the colour of the thermally modified timber product can beemployed. Examples of suitable colourless glues include polyurethanes,isocyanates and melamine-urea formulations. To achieve the desired tintin the glue a suitably coloured dye or pigment would be added to theglue. The dye or pigment used may not necessarily be the same dye orpigment used to colour the wood as the chemistry of the wood versus theglue is different.

Timber modification processes are processes that result in modificationof the structure of the wood and result in increased resistance todegradation by fungi, insects, bacteria and/or algae. Typically thetimber modification process does not comprise the application of achemical treatment compound that imparts long-term biocidel protectionto the timber. Such timber modification processes will be known to thoseof skill in the art. Suitable timber modification processes include:

-   -   thermal modification    -   resin impregnation    -   oil impregnation    -   acetylation; and    -   furfurylation,

The inventors have shown that thermally modified laminated timber boardsexhibit an increase in the stability of the timber. Specifically, theinventors have shown (see example 5) that thermally modified laminatedtimber has better weathering characteristics than standard preservativetreated laminated timber. Thermal modification is preferably carried outprior to lamination of the board to avoid potential issues with gluefailure which can occur when glues are heated during thermalmodification.

In addition to the increased stability of the timber, the thermalmodification process provides a permanent colour change to the timberthat penetrates throughout the timber. Laminated timber has the naturaldisadvantage of having a variety of different layers of wood beingformed into a single board. As can be seen from FIG. 17, there isnatural variation in the colour of each lamina. This is caused firstlyby the variation in growth over the year with lighter rings (earlywood)being followed by latewood (darker rings). Secondly, the heartwood 5 isdarker while the sapwood 6 is generally lighter in colour. This meansthat when laminated into a block and cut into boards to provide theappearance of a vertical grain orientation (as described below), thefinal product may have a striped effect that is undesirable for manyapplications. The inventors have found that when thermal modification ofthe layers is used, a more consistent colour is imparted to thedifferent layers such that the contrast between them is decreased. Thisnormalisation effect results in a laminated product with a consistentcolour across the surface of the timber. Preferably the colour acrossthe surface of the timber differs by less than L=10 or L=5 when assessedusing the CIELAB colour space. If the resultant colour is acceptable tothe user of the timber, no further colouring steps (as described below)may be needed. The inventors have also found that thermal modificationdecreases the visibility of the lamination glue lines that are presentin laminated timber as described above.

It has been found that thermally modifying the timber results in timberof increased exterior durability and therefore allows the timber to beused without preservative treatment in many above ground applications.Preferably, the thermal modification is carried out at a temperature ofbetween about 200° C.-260° C. Preferably the temperature is in a rangeof 200-260° C., or about 250° C., about 240° C., about 230° C., about220° C., about 210° C., or about 200° C. In some embodiments, thetemperature of the thermal modification may be as low as 180° C. Theinventors have found that thermally modifying the timber at 200-240° C.imparts durability and stability that provides a suitable product forexterior applications (e.g. cladding, decking) in addition to a mediumdark brown colour. 180° C.-200° C. does provide increased stability butonly gives a lighter brown colour.

The duration of treatment at the preferred temperature of 200-240° C. ispreferably 2-4 hours, or approximately 3 hours. In some embodiments, thetreatment may be from 1-6 hours.

Prior to thermal modification at the temperatures outlined above, thetimber is preferably dried to reduce moisture content to substantially0%. In one embodiment, drying is achieved by the application of heat andoptionally steam to heat the timber to 130° C. The duration of thedrying step depends on the original moisture content of the timber.

In some situations, for example where the timber may be subject totermite attack, a chemical preservative may also be used. Thermallymodifying the wood using a temperature in these ranges has been shown toreduce decay, (for example by the common brown rot fungus A. xantha),surface checking and weight loss as a result of wood degradation.Although wood can be thermally modified at lower temperatures, such asabout 165° C., such temperatures are unlikely to increase the stabilityof the wood and will have minimal effect on the colour.

In one embodiment, thermal modification is carried out in a highpressure cylinder and involves a high pressure steam treatment of kilndried timber. Preferably the kiln dried timber has a moisture content ofabout 16% or less.

A high pressure cylinder or kiln system that has been specificallydesigned for the elevated temperatures associated with thermalmodification could also be used for the thermal modification step. Suchthermal modification kilns, as offered, by way of example, by Tekmaheator Stellac, would be well known to the skilled person in the art. Closedcell thermal modification processes are also suitable for use as athermal modification process. Such closed cell systems, as offered, byway of example, by Wood Treatment Technology, would be known to those ofskill in the art. In one embodiment, closed cell thermal modification iscarried out at between 150° C. and 190° C., more preferably 160-180° C.

At 180 to 220° C. the look of Western Red Cedar is achieved. Elevatedtemperatures can result in a decrease in structural integrity of thetimber. Thus, while higher temperatures may result in a more desirabledarker colour, the resultant loss of structural integrity dictates thefinal applications for which the timber can be used. Thermalmodification is preferably carried out over a period of between about 2days and about 4 days, more preferably over 3 days to give a completelycoloured and dried product (approximately 6-8% moisture content).

In one embodiment, thermal modification of the timber providespreservative properties to the timber. In particular, the thermallymodified wood has increased resistance to degradation by fungi, insects,bacteria and/or algae. The use of thermal modification instead of achemical preservative compound treatment provides advantages to the userincluding:

-   -   reduced cost of treatment and preservative compounds;    -   reduced toxicity to animal/human health;    -   reduced toxicity to other species and therefore lower        environmental impact.

Further methods of timber modification may be used to achieve colouringand/or other desirable properties such as an increase in surfacehardness, stability and/or durability. Suitable treatments includeacetylation, furfuryl modification, resin impregnation and oilimpregnation.

Timber modification by way of acetylation involves the reaction of achemical reagent with the wood structural polymeric constituents toresult in the formation of a covalent bond between the reagent and thewood substrate. The product obtained contains acetyl groups bonded tohydroxyl (OH) sites in the wood cell wall. Although the reaction cantake place using ketene, acetic acid, or acetyl chloride, the mostuseful process is acetylation of wood due to reaction with aceticanhydride. Methods for the acetylation of wood will be known to those ofskill in the art. Acetylated wood's durability is Class 1, which matchesand in some cases exceeds the durability of many hardwood species.Durability is assessed by measuring weight loss over time in exposedconditions.

Furfuryl modified wood undergoes a process known as furfurylation whichuses furfuryl alcohol to modify the cell structure of the wood andthereby increase surface hardness, stability and durability. Colour mayalso be modified by using this technique. Methods to achievefurfurylation of wood are known to those of skill in the art.

Resin impregnation involves using pressure to force organic ornon-organic-based resins e.g. urea formaldehyde or a combination of ureaand starch-based emulsion or pine resin into the wood. This willincrease the stability, durability and/or surface hardnesscharacteristics of the timber. Colour may also be modified by using thistechnique.

Oil impregnation involves the introduction of oil to a timber via vacuumor pressure treatment processes. A variety of oils may be used includinglinseed, olive, pine or a mineral oil. The oil treated wood showsgreater resistance to fungal decay, and has better dimensional stabilitythan untreated wood. Methods for oil impregnation of wood are known inthe art and skilled persons will appreciate such methods. Oilimpregnation includes the use of oil-heat treatment processes. The useof oil-heat treatment has utility in modifying the timber and impartingstability and aesthetic characteristics. Oil impregnation allows thefast application of the heat to the wood, and excludes air during thetreatment phase thus reducing the scope for strength loss that can occurin other heat treatment systems.

In certain embodiments, the present invention involves the colouring thetimber with a desirable market colour. For some applications, it isdesirable to colour the timber throughout its cross-section. Among othermethods, this can be done by (1) thermal modification at a selected endpoint temperature to give the desired colour or (2) by use of a chemicalcolourant that is added during the preservative treatment process. Othertimber modification methods that can provide colouring includefurfurylation and resin impregnation. It is also possible to use apreservative having inherent colour due to its chemistry. Combinationsof colouring options can also be used. In particular, having colourthroughout means that if the timber needs to be sanded back forremediation work, the colour will be the same throughout. Thisremediation ability provides a particular benefit to the user.

In one embodiment, the step of colouring the timber is achieved bycarrying out the step of treating the timber using thermal modification.In this embodiment, the step of colouring the timber is achievedconcurrently with the step of thermal modification of the timber.Further colouration may be included if desirable.

Thermal modification changes the colour of timber throughout the timber.The end colour achieved is dependent mainly on the end-point temperatureat which thermal modification is carried out. Thus, the higher theend-point temperature, the darker the wood becomes throughout.Variations in colour can be achieved by altering the end-pointtemperature and uniform colour throughout the timber can be achieved.One advantage of being able to control the colour is that the timber canbe made to mimic the appearance of other species of timber. This allowsthe end user to achieve a desired appearance for exterior applications.The lightness of the thermally modified timber is measured by theL-value (lightness value) of the CIELAB colour space as specified by theInternational Commission on Illumination. Measurement of the L-value canbe carried out by methods known to those of skill in the art ofcolorimetry using appropriate colorimeters such as a Minolta ChromameterCR-400, In particular embodiments, the thermal modification reduces thelightness L-value of the timber to less than 60 or, for a darker colourless than 50. In other embodiments, the L-value is between 30 and 60(e.g., 30 . . . 35 . . . 45 . . . 55 . . . and 60). In certainembodiments, for a three hour thermal modification treatment time at200° C., the L-value is 58. In other embodiments, for a three hourthermal modification treatment time at 220° C., the L-value is 47. Insome embodiments for a three hour thermal modification treatment time at240° C., the L-value is 34. In one embodiment, the thermal modificationtemperature is between 200° C. and 240° C. and the L-value is between 30and 62.

The use of a chemical colourant to colour the wood throughout its wholecross-section typically involves the impregnation of a dye or pigment tothe timber. The dye or a pigment is preferably naturally occurring andmust be chemically compatible with any preservative treatment beingused. Use of a colourant ensures a particular colour is achieved for thefinal wood product. The colourant, if used, may be applied concurrentlywith a preservative, and if desired a suitable wetting agent (surfactantsystem) can be used to assist penetration. The wood may be coloured bythermal modification, addition of a colourant, by use of a preservativewith inherent colour, or other colouring methods, prior to or subsequentto lamination, or by incorporating the colourant into a pre-coating ofthe final product.

Chemical preservative treatment compounds may be used in addition tothermal modification and can be either a solvent-based treatment or awater-based treatment. Examples of suitable solvent-based preservativesinclude, TBTN, TBTO, Copper Napthenate, tri-azoles such as1-[[2-(2,4-dichlorophenyl)-4-propyl-1,3-dioxolan-2-yl]methyl]-1,2,4-triazole(Propiconazole) and(RS)-1-(4-chlorophenyl)-4,4-dimethyl-3-(1,2,4-triazole-1-yl-methyl)pentan-3-ol(Tebuconazole) and termidicide preservatives such as 3-phenoxybenzyl-(1RS)-cis,trans-3-(2,2-dichlorovinyl)-2,2-dimethylcyclopropane carboxylate(Permethrin) and/orN-[1-[(6-chloro-3-pyridyl)methyl]-4,5-dihydroimidazole-2-yl]nitramide(Imidacloprid). Examples of suitable water based preservatives includeCCA, ACQ and Copper Azole. It is also an option to use a preservativethat has inherent colour due to its chemistry (e.g. ACQ) if that meetscolour requirements.

Chemical preservative compounds are effective at limiting wooddegradation by their biocidal (typically fungicidal or insecticidal)properties. However, they do have limitations in that the compounds usedare, by their nature, toxic to many organisms and may have detrimentaleffects on animal/human health, especially following prolonged exposure.

The process of colouring the wood by use of a chemical colourantincorporated into the preservative treatment may be carried out eitherbefore or after lamination of individual boards. Where the wood iscoloured by thermal modification, a subsequent preservation step may becarried out either before or after lamination of individual boards. Theorder is dependent on the nature of the preservative treatment. Forexample, where the preservation step involves high water uptake, thetimber will have to be subsequently re-dried before it can be laminated.Conversely, where the preservation step is solvent based or involves lowwater uptake, the timber may be laminated prior to the preservativetreatment being undertaken. If necessary, surfactant systems, as wouldbe known in the art, can be used to ensure effective penetration ofpreservatives or colourants.

Use of a colourless glue or an appropriately tinted glue alone is oftennot enough to sufficiently mitigate the appearance of glue lines to meetsome customer requirements. Accordingly, although thermal modificationhas been shown by the inventors to provide some degree of disguising ofthe glue lines, some unsightly glue lines (or join lines) may remainevident in the surface of the timber following lamination. In oneembodiment, in order to create a higher quality product, it is desirablethat these glue lines are obscured or disguised by a surface finishingtechnique. One method of surface finishing appropriate to reduce thevisibility of the glue lines is the cutting of striations into thesurface of the timber at predetermined intervals and depths. Striationsmay have a width and depth of 1 mm or more and run parallel to the gluelines such that they lie along the glue lines themselves. In aparticular embodiment of the present invention, striations of 1 mm to 5mm are cut into the timber surface. The pitch between adjacentstriations may be about 3 mm and the raised surface between adjacentstriation channels may be approximately 2 mm. The striations may layalong individual glue lines. Striations may be formed by any suitableprocess. The subsequent use of a surface finishing technique to producethe required striations on the surface of the wood, preferably band sawnprocessing, micro-reed processing or brushing techniques, results in aproduct which closely mimics the aesthetic and stability characteristicsof high performance timbers referred to herein, such as Western RedCedar and Kwila.

It is advantageous to provide a laminated board with striations of lessthan 1 mm to provide a suitable aesthetic appearance. The surfacefinishing process could be used to provide wider striations if desired,but preferably of no more than about 2.5 mm in width, to disguise (i.e.reduce the visibility of) the lamination glue lines in the laminatedboard. In addition, it would be useful for the laminated product to beable to mimic the look of species including Western Red Cedar, Kwila,Teak, Vitex, Ipe, Balau, Bankirai or other commonly used timbers, whensupplied for appropriate applications. It has been found that the use ofstriations, when used in conjunction with the other steps of theinvention, provides a surprisingly effective mimicking effect. Such aneffect provides a desirable product to the market for use in similarapplications to other species of timber, such as those described above.

With respect to aesthetics, in cladding applications, a brushed or bandsawn look is often desired, and structural integrity is less of aconcern. Typically, the brushing technique is employed as thenon-uniform appearance of multiple striations is appealing. In contrast,in decking applications, the micro-reed process will likely be morepopular although the brushing look and even the band sawn look may beutilised. Striations may be added to any surface of the board and aretypically added to exposed surfaces to provide aesthetic appeal.Preferably, the striations are added to the face of the board.

The surface of the timber can thus be finished using striations that areproduced by:

-   -   (i) a band-sawn effect, preferably applied during sawing of the        laminated block into individual boards    -   (ii) a micro-reed effect, preferably applied during profiling of        the boards in a timber planar operation    -   (iii) a brushed effect, preferably applied using a metallic        brushing tool that is a standalone piece of equipment or has        been adapted to be used in a standalone timber planar operation.

The inventors have found that use of striations of less than 1 mm inwidth has a particular advantage in allowing a mimicking of theappearance of other species of timber when used in conjunction with theother processes of the invention.

Micro-reed process and brushing techniques are capable of formingstriations of less than 1 mm in width and therefore both provide a meansof producing a quality timber product with an aesthetically pleasingsurface finish where the glue lines are camouflaged. The use of finerstriations also avoids the need to ensure that individual striations liealong individual glue lines. These striations typically run parallel tothe lamination glue lines.

The micro-reed effect is typically applied during profiling of theboards in a timber planar operation. The profiling is done using knivesdesigned to cut a specific “micro-reed” pattern which comprises ridgesand bumps. These knives are fitted into the profiling machine to obtainthe desired surface finishing effect. Preferably, the profiling andaddition of the micro-reed effect is obtained in a single operation.Preferably the ridges and bumps are of approximately 0.2-1.0 mm in widthand have a length that is longer than the width wherein the length isaligned substantially lengthwise along the board.

The brushing technique is randomised in the sense that it involves theuse of a metallic or nylon brushing tool and results in non-uniformstriations. This tool is adapted to be used in a timber planer operationsuch that the surface of the board contacts the brushing tool as itpasses beneath it, leaving a brushed appearance on the board surface.The brushing tool can also be used as a standalone piece of equipment.

Striations can also be applied that are largely perpendicular to theglue lines and the most common method would be to create a band sawneffect obtained during cutting with a band saw. These are less effectiveat directly covering the glue line, but do create a surface that is moreaesthetically pleasing than the bare exposed lamination glue lines andwill be desirable in some applications where a more rustic look isrequired.

The inventors have found that when the wood is coloured throughout bythermal modification and laminated to provide the appearance of avertical grain orientation with optional surface finished withstriations (such as a micro-reed, brushed or band sawn appearance), atimber product is produced which mimics the appearance of more expensivetimbers, shows enhanced stability characteristics, and has a laminationglue line that less visible. The appearance and stability of timber suchas Western Red Cedar, Kwila, Teak, Vitex, Ipe, Balau, and/or Bankiraiand other hardwoods can be obtained that was previously unobtainable forsoft woods when used as a single solid board.

The ability to mimic such characteristics of other species of timberusing radiata or other low value wood species and cuts is of particularadvantage. In addition, the laminated wood product can be subjected toremedial work (e.g. sanding) without loss of colour thus adding to theaesthetics and usefulness of the product.

The timber processed according to the methods of the present inventioncan be used in cladding and/or decking applications in place of moreexpensive hardwoods as it can give the appearance of a high qualitytimber product which has not been laminated. The final application isdependent only on the structural integrity requirements and aestheticlook the customer desires. Thus, the method of the present inventionprovides a timber product which mimics the appearance of another timber,for example Western Red Cedar, Kwila, Teak, Vitex, Ipe, Balau and/orBankirai, and has enhanced stability.

In another aspect the present invention provides a method of processingtimber which enhances the stability and aesthetic characteristics of thetimber in a more simplified and cost effective manner by the addition ofa coating to the surface of the timber. This method includes the stepsof:

-   -   a. thermal modification; and lamination with a colourless or        tinted glue to produce the appearance of a vertical grain        orientation on a face of the timber; and    -   b. surface finishing; and    -   c. colouring the surface of the timber in final form through        addition of a colourant (also known as a tint) in a water-based        coating, prior to installation (“pre-coating”).        Coatings may also be applied to any of the previous embodiments        of the invention described herein.

Coatings are normally clear oil-based or water-based chemicalformulations that are applied manually to timber decks or cladding postinstallation to act as a barrier against water and sunlight (UV) whentimber is used in an exterior situation. This prevents the timber fromweathering or “silvering off” and maintains the original look of thetimber. Coatings are transparent so that the underlying grain structureof the wood is still visible, unlike a painted timber board.

Pre-coating of timber boards is undertaken in a factory setting prior todelivery and installation that allows a more uniform application. Thecoating is applied using purpose-designed equipment such as a spraysystem or vacuum coater. During this process it is possible to tint orcolour the coating formulation to achieve a coloured product.

Coating of timber boards has limitations in that the coating (and hencethe colour) is only applied to the surface and will wear off after timein service. This means re-coating in-situ will be necessary if the enduser wishes to maintain the look and if a similar colour is required thechemical formulation with matching colourants will need to be madeavailable at a retail level to the end user.

This aspect of the present invention is particularly useful forconsumers who desire a coated finish to their decking or cladding. Thecombination of thermal modification, lamination with the stated gluesand colourant in a water based coating being able to provide analternative to more expensive timber such as hardwood options. Optionalsurface finishing techniques as described herein can also be used toenhance the timber product further.

EXAMPLES Example 1: Steamed Laminated, Brushed Radiata Pine Cladding

Clear grade green boards of 100 mm×25 mm were sawn from 100% sapwood andwere steamed at 165° C. for 4 to 6 hours. The boards were then kilndried using conventional medium temperature kilns with a typical radiatapine drying schedule. A preservative treatment was then carried outusing a solvent-based LOSP process to H3.1 clear. The boards wereblanked to 100 mm×23 mm using a conventional planing machine and werethen laminated into a block with a clear polyurethane exterior-gradeadhesive (Henkel Purbond) taking care to ensure the grain of each boardwas orientated in the flat-sawn direction. The resultant block wassliced, using a conventional band saw, into a number of nominal 150mm×25 mm boards that exhibited a vertical grain appearance. The boardswere profiled using a conventional planing machine using a band sawnfinish (FIGS. 5 to 8). The boards were then coated using a vacuum coaterwith an Akzo Nobel, water-based polyurethane.

Assessment of Timber for Aesthetic Qualities

The samples of timber discussed above were subjected to qualitativeanalysis of the characteristics described below. The visibility of gluelines and colour contrast were compared to a true vertical grainorientation timber sample. The colour richness comparison was assessedin comparison to a Western Red Cedar board:

Feature Treated sample Visibility of glue lines (1 = least visible, 5 =4 most visible) Colour contrast between laminated layers (1 = 4 leastcontrast, 5 = most contrast) Colour richness (1 = least similar, 5 =most 3 similar)This test shows that despite providing a suitable laminated product, thevisibility of glue lines and contrast between the laminated layerslowers the overall aesthetic qualities of the treated board. Inaddition, the colour richness of the board is not close to a moreexpensive species such as Cedar.

Example 2: Preservative Coloured, Laminated, Profiled Radiata PineDecking

Clear grade green boards of 150 mm×35 mm were sawn from 100% sapwood andwere kiln dried using conventional medium temperature kilns with atypical radiata pine drying schedule. The boards were then preservativetreated using a water-based process with ACQ to H3.2. The treated boardswere blanked to 150 mm to 32 mm using a conventional planning machineand were subsequently laminated into a block with a clear polyurethaneexterior-grade adhesive (Henkel Purbond) taking care to ensure the grainof each board was orientated in the flat-sawn direction. The block wassliced, using a conventional band saw, into a number of nominal 150mm×25 mm boards that exhibited a vertical grain appearance. The boardswere then profiled using a conventional planing machine with attachmentto brush striations of less than 1 mm in width into the surface of theboards (FIGS. 1-4).

Assessment of Timber for Aesthetic Qualities

The samples of timber discussed above were subjected to qualitativeanalysis of the characteristics described below. The visibility of gluelines and colour contrast were compared to a true vertical grainorientation timber sample. The colour richness comparison to a moreexpensive hardwood was assessed in comparison to a Western Red Cedarboard:

Feature Treated sample Visibility of glue lines (1 = least visible, 5 =3 most visible) Colour contrast between laminated layers (1 = 3 leastcontrast, 5 = most contrast) Colour richness (1 = least similar, 5 =most 3 similar)This test shows that despite providing a suitable laminated product, thevisibility of glue lines and contrast between the laminated layers stillcompromises the overall aesthetic qualities of the treated board.Although the appearance of the glue lines and contrast is improved whencompared to LOSP treatment, the overall aesthetics of the treated timberis lacking when compared to true vertical grain timber. In addition, thecolour richness of the board is not close to a more expensive speciessuch as cedar.

Example 3: Laminated, Profiled, Pre-Coating Coloured Radiata PineDecking

Clear grade green boards of 150 mm×35 mm were sawn from 100% sapwood andwere kiln dried using conventional medium temperature kilns with atypical radiata pine drying schedule. The boards were then preservativetreated using a water-based process with ACQ to H3.2. The treated boardswere blanked to 150 mm to 32 mm using a conventional planning machineand were subsequently laminated into a block with a clear polyurethaneexterior-grade adhesive (Henkel Purbond) taking care to ensure the grainof each board was orientated in the flat-sawn direction. The block wassliced, using a conventional band saw, into a number of nominal 150mm×25 mm boards that exhibited a vertical grain appearance. The boardswere then profiled using a conventional planing machine with attachmentto brush striations of less than 1 mm in width into the surface of theboards. Finally, the boards were coated using a vacuum coater with AkzoNobel, water-based polyurethane with a tint added to give a differentsurface colour to the board than the natural colour found with ACQ (asExample 2 above).

Assessment of Timber for Aesthetic Qualities

The samples of timber discussed above were subjected to qualitativeanalysis of the characteristics described below. The visibility of gluelines and colour contrast were compared to a true vertical grainorientation timber sample. The colour richness comparison to a moreexpensive hardwood was assessed in comparison to a Western Red Cedarboard:

Feature Treated sample Visibility of glue lines (1 = least visible, 5 =2 most visible) Colour contrast between laminated layers (1 = 2 leastcontrast, 5 = most contrast) Colour richness (1 = least similar, 5 =most 4 similar)This test shows that the visibility of glue lines and contrast betweenthe laminated layers is improved when using a tinted coating differentto the natural colour of the board. The overall aesthetics of the boardare improved with a better rating for colour contrast and similarity tothe overall aesthetic qualities of the treated board. Although thecontrast is improved when compared to LOSP or ACQ treatment alone, thecolour richness and visibility of glue lines is still lacking whencompared to true vertical grain timber or the Western Red Cedar sample.

Example 4: Use of a Colourant, Co-Formulated with a Preservative

Trial using treatment solution including a micronized pigment (0.1%hostafine blue pigment—CLARIANT) using vacuum/pressure techniques toshow penetration effects.

Most pigments tend to have poor penetration in wood due to the filteringeffect of the closely packed fibres and therefore a surfactant systemwith suitable wetting properties was used to carry the activeingredients into the timber. The surfactant system also assisted tomaintain the actives in a stable suspended condition in the treatmentsolution in the presence of timber extractives and under plantconditions.

The surfactant system used in this trial comprised a proprietarycombination of:

1. An amphoteric surfactant; and

2. A non-ionic surfactant.

Timber

Kiln dried radiata pine samples were used, these were 20 mm thickdecking boards and 11 mm thick sarking boards. The boards were sealed ontheir end grain using 2 coats of Resene Quick dry acrylic primer.

Trial Conditions

Action Pressure (Kpa) Duration (minutes) Initial vacuum −80 5 Treatmentchamber Solution drawn into 1 flooding chamber under vacuum Soak  0 2Treatment chamber Atmospheric 1 draining pressure-gravity Final Vacuum−80 5Foam Control

There were no signs of foam control problems even under vacuum and highagitation of the treatment solution.

Solution Uptake

An average uptake of 230 liters/cubic meter was achieved.

Penetration of Dye

Samples were cross cut and split using a chisel, full penetration of thepigment to a level of at least 10 mm was evident (full penetration of 20mm boards). Penetration on dense annular rings and heartwood was lowerthan in other parts of the timber but 10 mm was evident.

Conclusion

Hostafine pigments are capable of deep penetration into timber usingvacuum/pressure techniques, preferably together with a suitable wettingagent. Timber products produced by methods of the invention that mimicthe look of Cedar and which are suitable for applications such ascladding and decking can be seen in FIGS. 1 to 8. The completepenetration of the colour can be seen in FIGS. 1 and 5.

Example 5: Exterior Weathering Characteristics of Laminated Timber

Weathering characteristics were compared between thermally modified andpreservative treated timber. All timber was laminated to produce theappearance of a substantially vertical grain.

Methodology

“Clears” grade timber was thermally modified according to the followingmethod:

-   -   a. A kiln (Mahild) was slowly elevated in temperature to 130° C.        using heat and steam until the moisture content of the wood was        essentially 0%;    -   b. The wood in the kiln was then heated further until it reached        220° C. The Kiln was held at the modification temperature for 3        hours;    -   c. The kiln was allowed to cool and the wood was reconditioned        with steam to 6-7% MC. Once cool enough the wood was extracted        from the kiln.

H3.2 alkaline copper quaternary (ACQ) kiln dried preservative treatedradiata pine boards were used as a comparator. Both sets of treatedtimber with a predominantly flat sawn grain orientation were machinedand laminated into 150×160 mm blocks with Purbond HBS polyurethaneadhesive according to AS/NZS1328 glue lamination standard. After gluecure, the boards were then band sawn perpendicular to the glue line into150×23 boards resulting in the appearance of a substantially verticalgrain (VG) orientation. The lightness L-value of the thermally modifiedboards was visually assessed against a colour palette for pine andexpressed in terms of the CIELAB Color Space.

The boards were then machined into weatherboard profiles with band sawnfaces. 1.2 m Length samples were cut randomly from long length pieces.

Water based and oil based semi-transparent stain was applied to theboards-face, back and ends

The boards were installed onto exposure racks at a test site with thefollowing specifications:

-   -   Fixed with stainless steel flat head ring shank nails in the        same manner    -   North facing at 45 degree angle    -   Proximity to native bush, marsh lands and sea spray

The boards were exposed and the weather conditions were recorded atregular intervals. The test racks were visited approximately 6 monthsafter installation and then at approximately 6 month intervals afterthis. Aesthetic assessment of the boards was also carried out at thestart of the trial.

Results

Assessment of Timber for Aesthetic Qualities

The timber had an L-value of approximately 47. The samples of timberdiscussed were subjected to qualitative analysis of the characteristicsdescribed below. The visibility of glue lines and colour contrast werecompared to a true vertical grain orientation timber sample. The colourrichness comparison to a more expensive hardwood was assessed incomparison to a Western Red Cedar board:

TABLE 1 Laminated thermally Feature Laminated ACQ sample modified sampleVisibility of glue lines 3 4 (1 = least visible, 5 = most visible)Colour contrast between 3 1 laminated layers (1 = least contrast, 5 =most contrast) Colour richness 3 5 (1 = least similar, 5 = most similar)Weather conditions recorded Temperature and Humidity Highest Temperature30.6° C. at 4:00 p.m. on day 291 Lowest Temperature 0.1° C. at 6:13 a.m.on day 95 Highest Dew Point 24.2° C. at 8:18 a.m. on day 309 Lowest DewPoint −1.5° C. at 12:20 p.m. on day 76 Lowest Wind Chill 0.1° C. at 6:13a.m. on day 95 Temperature Highest Heat Index 35.2° C. at 5:30 p.m. onday 294 Highest Humidity 100% at 2:42 a.m. on day 2 Lowest Humidity  30%at 12:55 p.m. on day 219 Highest Daily Range 16.4° C. on day 51 LowestDaily Range 0.4° C. on day 304 Rainfall Highest Rain Rate 79.1 mm/hr at7:16 a.m. on day 146 Highest Hourly Rainfall 309.6 mm at 12:00 a.m onday 303 Highest Daily Rainfall 35.4 mm on day 45 Wind Highest Wind Gust64.8 km/h at 10:21 a.m on day 37 Highest Wind Speed 50.0 km/h at 9:25p.m. on day 227 Average Pressure Lowest Pressure (sl) 983.4 mb at 5:23p.m. on day 172 Highest Pressure (sl) 1039.4 mb at 8:57 a.m. on day 106Assessment of lamination integrity Treatment Day of assessmentLamination integrity ACQ treated 193 4 407 2 Thermally modified 193 5407 5 Lamination integrity was assessed on a 5 point scale as follows: 5= No evidence of delamination 4 = Minor regions of partial delamination(less than 2 cm) 3 = More extensive partial delamination (less than 10cm) some fibre tear (wood fibre splitting from the rest of the timber) 2= Extensive delamination (greater than 10 cm sections) and extensivefibre tear 1 = complete delamination and joint failureLaminated ACQ Observations:

At the first visit (day 193), there was evidence of glue delamination atthe ends of the ACQ boards. During further visits partial delamination(where wood fibre pulls away from the rest of the board at the glueline) was observed occurring in the middle of the boards. The partialdelamination developed quite quickly and then stopped developing furtherafter approximately 12-18 months exposure. FIGS. 11 to 14 show sampleboards with partial delamination.

Laminated Thermally Modified Timber Observations:

After 24 months' exposure, the TMT substrate was virtually perfect withno delamination evident. Some minor ‘ring failure’ (cracking at thegrowth rings) was observed, but no delamination. FIGS. 15 and 16 showsample boards with no evidence of delamination.

Conclusions

After three years weathering exposure there was a marked difference inweathering performance between laminated vertical grain TMT andlaminated vertical grain ACQ boards.

Pulling away of timber edges at the glue lines (delamination) wasvirtually eliminated by substituting with TMT.

In addition, in thermally modified timber, the visibility of glue lineswas reduced, the contrast between layers was reduced and the colourrichness was increased. These results indicate that the overallaesthetics of the timber were improved in concert with the stability.

The entire disclosures of all applications, patents and publicationscited above and below, if any, are herein incorporated by reference.Reference to any prior art in this specification is not, and should notbe taken as, an acknowledgement or any form of suggestion that thatprior art forms part of the common general knowledge in the field ofendeavour in any country in the world. Wherein the foregoing descriptionreference has been made to integers or components having knownequivalents thereof, those integers are herein incorporated as ifindividually set forth. Various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the invention and withoutdiminishing its attendant advantages. It is therefore intended that suchchanges and modifications be included within the scope of the invention.

We claim:
 1. A method of using timber boards with a substantially flatgrain to produce a laminated board with enhanced dimensional stabilityand aesthetic characteristics, the method comprising: a) taking at leasttwo timber boards originally cut from a tree in a substantially flatgrain orientation; b) laminating a flat grain face of each boardtogether by gluing to produce a laminated block; and c) cutting thelaminated block substantially perpendicular to the grain to producelaminated boards comprising a front and back face having the appearanceof a substantially vertical grain and showing at least one glue line,wherein the method further comprises treatment and colouring of thetimber boards, laminated block or laminated boards by thermalmodification, and wherein the method does not include the step oftreating the timber with a chemical preservative compound.
 2. The methodof claim 1, further comprising the step of surface finishing comprisingthe addition of one or more striations to the front or back face of thelaminated boards.
 3. The method of claim 2, wherein the addition of oneor more striations reduces visibility of at least one glue line betweenthe laminated layers.
 4. The method of claim 1, wherein thermalmodification reduces the visibility of at least one lamination glueline.
 5. The method of claim 1, wherein thermal modification is carriedout at between 200° C. and 240° C.
 6. The method of claim 1, whereinthermal modification is carried out at a temperature between 200° C. and240° C. for a period of between 2 and 4 hours.
 7. The method of claim 1,wherein colouring the timber is further achieved by at least one of: i)furfuryl modification; ii) resin impregnation; and iii) use of acolourant.
 8. The method of claim 2, wherein surface finishing comprisesthe addition of striations selected from the group consisting of lessthan 2.5 mm width, less than 1 mm width, approximately 2.5 mm width andapproximately 1 mm width.
 9. The method of claim 1, wherein a lightnessL-value of the board is reduced by thermal modification to less than 62as measured by the CIELAB Color Space.
 10. The method of claim 1,wherein contrast in lightness between layers in the laminated board isless than L=10 when assessed using the CIELAB colour space.
 11. Themethod of claim 2, wherein the striations are added to the surface ofthe timber by at least one of: i) a band-sawn effect; ii) a micro-reedeffect; or iii) a brushed effect.
 12. The method of claim 1, wherein thetimber comprises a softwood timber species.
 13. The method of claim 1,wherein the timber comprises radiata pine, southern yellow pine, scotspine, ash, maple, beech, birch, aspen or rubber wood.
 14. The method ofclaim 1, wherein the timber is coloured to mimic the colour of adifferent wood.
 15. The method of claim 14, wherein the different woodis Western Red cedar, Kwila, Teak, Vitex, Ipe, Balau or Bankirai.